Process for producing a multilayer article

Abstract

A multilayer molded article including a resin body and a skin material having little or no wrinkles or breakage in the skin material is molded by molding a resin melt and the skin material in the mold while removing the air trapped between the skin material and the mold.

What is claimed is: 
     
       1. A process for producing a multilayer molded article comprising a resin body and a skin material, which process comprises the steps of: supplying skin material between a male mold and a female mold,   supplying a resin melt between the skin material and one of the male and female molds, and   closing the molds to mold the resin melt while removing any air trapped between the skin material and at least one of the molds at a front edge line of the resin melt, wherein the air is removed through a pin hole made in the skin, through a puncture made in the skin, through a slit formed on an inner wall of at least one of the molds, or through a heat-resistant porous member embedded in an inner wall of at least one of the molds.   
     
     
       2. A process for producing a multilayer molded article comprising a resin body and a skin material, which process comprises the steps of: supplying skin material between a male mold and a female mold,   supplying a resin melt between the skin material and one of the male and female molds, and   closing the molds to mold the resin melt while removing any air trapped between the skin material and at least one of the molds at a front edge line of the resin melt, wherein the air is removed through a heat-resistant porous member embedded in an inner wall of at least one of the molds and a slit formed in an inner wall of at least one of the molds.   
     
     
       3. A process for producing a multilayer molded article comprising a resin body and a skin material, which process comprises the steps of: supplying skin material between a male mold and a female mold,   supplying a resin melt between the skin material and one of the male and female molds, and   closing the molds to mold the resin melt while removing any air trapped between the skin material and at least one of the molds at a front edge line of the resin melt, wherein the air is removed through a pin hole made in the skin by a pin affixed on an inner wall of at least one of the molds and through a heat-resistant porous member embedded in an inner wall of at least one of the molds and a slit formed in an inner wall of at least one of the molds.   
     
     
       4. A process for producing a multilayer molded article comprising a resin body and a skin material, which process comprises the steps of: supplying skin material between a male mold and a female mold, supplying a resin melt between the skin material and one of the male and female molds, and   closing the molds to mold the resin melt while removing any air trapped between the skin material and at least one of the molds at a front edge line of the resin melt, wherein the air if removed through a puncture made in the skin adjacent to a mold hole formed on an inner wall of at least one of the walls and through a heat-resistant porous member embedded in at least one of the molds and a slit formed on an inner wall of at least one of the molds.   
     
     
       5. The process according to claim 1, wherein the trapped air is removed through a slit formed on an inner wall of at least one of the molds. 
     
     
       6. The process according to claim 1, wherein the trapped air is removed through a pin hole made in the skin by a pin affixed on an inner wall of at least one of the molds. 
     
     
       7. The process according to claim 6, wherein said pin is attached to a spring or cushioning means. 
     
     
       8. The process according to claim 6, wherein said pin has a diameter of 0.1 to 2 mm. 
     
     
       9. The process according to claim 1, wherein the trapped air is removed through a puncture made in the skin adjacent to a mold hole formed in an inner wall of at least one of the molds. 
     
     
       10. The process according to claim 9, wherein said mold hole formed in at least one of the molds has a diameter of 2 to 6 mm and a depth of 11 to 30 mm. 
     
     
       11. The process according to claim 6, wherein a through hole is formed in at least one of the molds so as to communicate with said pin. 
     
     
       12. The process according to claim 9, wherein a through hole is formed in at least one of the molds so as to communicate with mold hole. 
     
     
       13. The process according to claim 1, wherein the trapped air is removed through a slit formed in an inner wall of at least one of the molds. 
     
     
       14. The process according to claim 13, wherein a through hole is formed in at least one of the molds so as to communicate with said slit. 
     
     
       15. The process according to claim 1, wherein the trapped air is removed through a heat-resistant porous member embedded in an inner wall of at least one of the molds. 
     
     
       16. The process according to claim 15, wherein a through hole is formed in at least one of the molds so as to communicate with said porous member. 
     
     
       17. The process according to claim 2, wherein a through hole is formed in at least one of the molds so as to communicate with said porous member. 
     
     
       18. The process according to claim 1, wherein the skin material is a material selected from the group consisting of woven fabric, non-woven fabric, metal net, thermoplastic resin fiber, paper, metal foil, thermoplastic resin sheet, thermoplastic resin foam, rubber foam and a laminate of at least two layers of said materials; and said resin melt is a resin selected from the group consisting of polypropylene, polyethylene, polystyrene, acrylonitrile-styrene-butadiene copolymer, nylon, ethylene-propylene copolymer and styrene-butadiene copolymer. 
     
     
       19. The process according to claim 3, wherein the trapped air is removed through said pin hole and said heat-resistant porous member. 
     
     
       20. The process according to claim 3, wherein the trapped air is removed through said pin hole and said slit. 
     
     
       21. The process according to claim 3, wherein said pin is attached to a spring or cushioning means. 
     
     
       22. The process according to claim 3, wherein said pin has a diameter of 0.1 to 2 mm. 
     
     
       23. The process according to claim 19, wherein said pin is attached to a spring or cushioning means. 
     
     
       24. The process according to claim 19, wherein said pin has a diameter of 0.1 to 2 mm. 
     
     
       25. The process according to claim 20, wherein said pin is attached to a spring or cushioning means. 
     
     
       26. The process according to claim 20, wherein said pin has a diameter of 0.1 to 2 mm. 
     
     
       27. The process according to claim 3, wherein the skin material is a material selected from the group consisting of woven fabric, non-woven fabric, metal net, thermoplastic resin fiber, paper, metal foil, thermoplastic resin sheet, thermoplastic resin foam, rubber foam and a laminate of at least two layers of said materials; and said resin melt is a resin selected from the group consisting of polypropylene, polyethylene, polystyrene, acrylonitrile-styrene-butadiene copolymer, nylon, ethylene-propylene copolymer and styrene-butadiene copolymer. 
     
     
       28. The process according to claim 19, wherein the skin material is a material selected from the group consisting of woven fabric, non-woven fabric, metal net, thermoplastic resin fiber, paper, metal foil, thermoplastic resin sheet, thermoplastic resin foam, rubber foam and a laminate of at least two layers of said materials; and said resin melt is a resin selected from the group consisting of polypropylene, polyethylene, polystyrene, acrylonitrile-styrene-butadiene copolymer, nylon, ethylene-propylene copolymer and styrene-butadiene copolymer. 
     
     
       29. The process according to claim 20, wherein the skin material is a material selected from the group consisting of woven fabric, non-woven fabric, metal net, thermoplastic resin fiber, paper, metal foil, thermoplastic resin sheet, thermoplastic resin foam, rubber foam and a laminate of at least two layers of said materials; and said resin melt is a resin selected from the group consisting of polypropylene, polyethylene, polystyrene, acrylonitrile-styrene-butadiene copolymer, nylon, ethylene-propylene copolymer and styrene-butadiene copolymer. 
     
     
       30. The process according to claim 4, wherein the trapped air is removed through said mold hole and said heat-resistant porous member. 
     
     
       31. The process according to claim 4, wherein the trapped air is removed through said mold hole and said slit. 
     
     
       32. The process according to claim 4, wherein the skin material is a material selected from the group consisting of woven fabric, non-woven fabric, metal net, thermoplastic resin fiber, paper, metal foil, thermoplastic resin sheet, thermoplastic resin foam, rubber foam and a laminate of at least two layers of said materials; and said resin melt is a resin selected from the group consisting of polypropylene, polyethylene, polystyrene, acrylonitrile-styrene-butadiene copolymer, nylon, ethylene-propylene copolymer and styrene-butadiene copolymer. 
     
     
       33. The process according to claim 30, wherein the skin material is a material selected from the group consisting of woven fabric, non-woven fabric, metal net, thermoplastic resin fiber, paper, metal foil, thermoplastic resin sheet, thermoplastic resin foam, rubber foam and a laminate of at least two layers of said materials; and said reisn melt is a resin selected from the group consisting of polypropylene, polyethylene, polystyrene, acrylonitrile-styrene-butadiene copolymer, nylon, ethylene-propylene copolymer and styrene-butadiene copolymer. 
     
     
       34. The process according to claim 31, wherein the skin material is a material selected from the group consisting of woven fabric, non-woven fabric, metal net, thermoplastic resin fiber, paper, metal foil, thermoplastic resins sheet, thermoplastic resin foam, rubber foam and a laminate of at least two layers of said materials; and said resin melt is a resin selected from the group consisting of polypropylene, polyethylene, polystyrene, acrylonitrile-styrene-butadiene copolymer, nylon, ethylene-propylene copolymer and styrene-butadiene copolymer. 
     
     
       35. The process according to claim 4, wherein said mold hole formed in at least one of the molds has a diameter of 2 to 6 mm and a depth of 11 to 30 mm.